How to replace Timing Chain & Sprockets on Ford Fusion & Mercury Milan?

The procedure is similar for both Ford, Lincoln and Mercury car models:----

Timing Chain & Sprockets

REMOVAL & INSTALLATION details are as follows:----

NOTE

During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan may cause engine failure.

1. Remove the engine front cover.
2. Rotate the crankshaft clockwise and align the timing marks on the Variable Camshaft Timing (VCT) assemblies.
   
   NOTE

   The special tool will hold the camshafts in the Top Dead Center (TDC) position.
3. Install the Camshaft Holding Tool onto the flats of the LH camshafts.
4. Install the Camshaft Holding Tool onto the flats of the RH camshafts.
5. Remove the 3 bolts and the RH VCT housing.
6. Remove the 3 bolts and the LH VCT housing.
7. Remove and discard the VCT housing seals. 
   
   
   
   Fig. Removing the VCT housing seals
8. Remove the 2 bolts and the primary timing chain tensioner.
9. Remove the primary timing chain tensioner arm.
10. Remove the 2 bolts and the lower LH primary timing chain guide.
11. Remove the primary timing chain.
12. Remove the crankshaft timing chain sprocket.
    
    
    

    

    Fig. Removing the crankshaft timing chain sprocket
13. Remove the 2 bolts and the upper LH primary timing chain guide.
14. Compress the LH secondary timing chain tensioner and install a suitable lockpin to retain the tensioner in the collapsed position.
    
    NOTE

    The VCT bolt and the exhaust camshaft bolt must be discarded and new ones installed. However, the exhaust camshaft washer is reusable.
15. Remove and discard the LH VCT assembly bolt and the LH exhaust camshaft sprocket bolt. Remove the LH VCT assembly, secondary timing chain and the LH exhaust camshaft sprocket as an assembly.
    
    NOTE

    It is necessary to tilt the camshaft holding tool toward the rear of the engine to access the rearmost secondary timing chain tensioner bolt.
16. Remove the 2 bolts and the LH secondary timing chain tensioner.
17. Compress the RH secondary timing chain tensioner and install a suitable lockpin to retain the tensioner in the collapsed position.
    
    NOTE

    The VCT bolt and the exhaust camshaft bolt must be discarded and new ones installed. However, the exhaust camshaft washer is reusable.
18. Remove and discard the RH VCT assembly bolt and the RH exhaust camshaft sprocket bolt.
19. Remove the RH VCT assembly, secondary timing chain and the RH exhaust camshaft sprocket as an assembly.
    
    NOTE

    It is necessary to tilt the Camshaft Holding Tool toward the rear of the engine to access the rearmost secondary timing chain tensioner bolt.
20. Remove the 2 bolts and the RH secondary timing chain tensioner.
    
    
    

    

    Fig. Removing the 2 bolts and the RH secondary timing chain tensioner
21. Remove the 2 bolts and the RH primary timing chain guide.
    
    
    

    

    Fig. Removing the 2 bolts and the RH primary timing chain guide

To install:

1. Install the RH primary timing chain guide and the 2 bolts and tighten to 89 inch lbs. (10 Nm).
   
   NOTE

   It is necessary to tilt the Camshaft Holding Tool toward the rear of the engine to access the rearmost secondary timing chain tensioner bolt.
2. Install the RH secondary timing chain tensioner and the 2 bolts and tighten to 89 inch lbs. (10 Nm).
   
   NOTE

   It is necessary to tilt the Camshaft Holding Tool toward the rear of the engine to access the rearmost secondary timing chain tensioner bolt.
3. Install the RH secondary timing chain tensioner and the 2 bolts and tighten to 89 inch lbs. (10 Nm).
4. Install the new VCT bolt and new exhaust camshaft bolt and the original washers. Tighten in 4 stages:
   1. Stage 1: Tighten to 30 ft. lbs. (40 Nm).
   2. Stage 2: Loosen one full turn.
   3. Stage 3: Tighten to 89 inch lbs. (10 Nm).
   4. Stage 4: Tighten 90°
5. Remove the lockpin from the RH secondary timing chain tensioner.
   
   NOTE

   It is necessary to tilt the Camshaft Holding Tool toward the rear of the engine to access the rearmost secondary timing chain tensioner bolt.
6. Install the LH secondary timing chain tensioner and the 2 bolts and tighten to 89 inch lbs. (10 Nm).
7. Assemble the LH VCT assembly, the LH exhaust camshaft sprocket and the LH secondary timing chain. Align the colored links with the timing marks.
8. Position the LH secondary timing assembly onto the camshafts.
9. Install the new VCT and the new exhaust camshaft bolt and the original washers. Tighten in 4 stages.
   1. Stage 1: Tighten to 30 ft. lbs. (40 Nm).
   2. Stage 2: Loosen one full turn.
   3. Stage 3: Tighten to 89 inch lbs. (10 Nm).
   4. Stage 4: Tighten 90°
10. Remove the lockpin from the LH secondary timing chain tensioner.
11. Install the crankshaft timing chain sprocket.
12. Install the primary timing chain with the colored links aligned with the timing marks on the VCT assemblies and the crankshaft sprocket.
13. Install the upper LH primary timing chain guide and the 2 bolts and tighten to 89 inch lbs. (10 Nm).
14. Install the lower LH primary timing chain guide and the 2 bolts. Tighten to 89 inch lbs. (10 Nm).
15. Install the primary timing chain tensioner arm.
16. Reset the primary timing chain tensioner.
    1. Rotate the lever counterclockwise.
    2. Using a soft-jawed vise, compress the plunger.
    3. Align the hole in the lever with the hole in the tensioner housing.
    4. Install a suitable lockpin.
       
       NOTE

       It may be necessary to rotate the crankshaft slightly to remove slack from the timing chain and install the tensioner.
17. Install the primary tensioner and the 2 bolts. Tighten to 89 inch lbs. (10 Nm). Remove the lockpin.
18. As a post-check, verify correct alignment of all timing marks.
19. Install new VCT housing seals.
    
    NOTE

    Make sure the dowels on the Variable Camshaft Timing (VCT) housing are fully engaged in the cylinder head prior to tightening the bolts. Failure to follow this process will result in severe engine damage.
20. Install the VCT housing and the 3 bolts. Tighten in the sequence shown to 89 inch lbs. (10 Nm).
    
    
    

    

    Fig. Identifying the LH VCT housing tightening sequence
    
    
    
    

    

    Fig. Identifying the RH VCT housing tightening sequence
21. Install the engine front cover.

2.3L Engine

Specific to:

Ford Fusion 2008-2009

Mercury Milan 2008-2009

WARNING

Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if you loosen the pulley bolt. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage can occur.

WARNING

During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan can cause engine failure.

1. Raise and safely support the vehicle.
2. Remove the timing chain/engine front cover.
3. Remove the timing chain tensioner, as follows:
   1. Compress the timing chain tensioner and insert a paper clip into the hole to retain the tensioner.
   2. Remove the 2 bolts and timing chain tensioner.
      
      
      

      

      Fig. Compress the timing chain tensioner and insert a paper clip into the hole to retain the tensioner (1). Then, remove the 2 bolts and timing chain tensioner (2)-2.3L engine
4. Remove the timing chain tensioner arm.
5. Remove the timing chain.
6. Remove the 2 bolts and the timing chain guide.
   
   WARNING

   The special tool 303-465 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
7. Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and the exhaust camshaft sprocket.
   
   WARNING

   The special tool 303-465 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
8. Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and the camshaft phaser and sprocket.

To install:

1. Install the camshaft sprockets and the bolts. Do not tighten the bolts at this time.
2. Install the timing chain guide and the 2 bolts. To install, tighten to 89 inch lbs. (10 Nm).
3. Install the timing chain.
4. Install the timing chain tensioner arm.
5. Install the timing chain tensioner and the 2 bolts. Remove the paper clip to release the piston. Tighten to 89 inch lbs. (10 Nm).
   
   WARNING

   The special tool 303-465 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
6. Using the flats on the camshafts to prevent camshaft rotation, tighten the bolts. Tighten to 53 ft. lbs. (72 Nm).
7. Install the engine front/timing chain cover.

3.0L Engine

Specific to:

Ford Fusion 2008-2009

Mercury Milan 2008-2009

WARNING

During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, can cause engine failure.

WARNING

Failure to verify correct timing drive component alignment will result in severe engine damage.

1. Remove the engine front/timing chain cover, as outlined in this section.
   
   WARNING

   This pulse wheel is used in several different engines. Install the pulse wheel with the keyway in the slot stamped 30RFF (orange in color).
2. Remove the ignition pulse wheel.
3. Install the crankshaft pulley bolt and washer.
4. Remove the 6 spark plugs
5. Rotate the crankshaft clockwise to position the crankshaft keyway in the 11 o'clock position and position the camshafts in the correct position. This will position the No.1 cylinder at top dead center (TDC):
   1. Verify that the camshafts are correctly located. If not, rotate the crankshaft one additional turn and recheck.
      
      
      

      

      Fig. Verify that the camshafts are correctly located. If not, rotate the crankshaft one additional turn and recheck-3.0L engine
6. Rotate the crankshaft clockwise 120 degrees to the 3 o'clock position to position the RH camshafts in the neutral position.
   
   
   

   

   Fig. Rotate the crankshaft clockwise 120 degrees to the 3 o'clock position to position the RH camshafts in the neutral position-3.0L engine
7. Verify that the RH camshafts are in the neutral position.
   
   
   

   

   Fig. Verify that the RH camshafts are in the neutral position-3.0L engine
8. Remove the RH timing chain tensioner arm:
   1. Remove the 2 bolts.
   2. Remove the tensioner.
   3. Remove the tensioner arm.
9. Remove the RH timing chain.
10. Remove the 3 bolts and the RH VCT assembly.
11. Rotate the crankshaft clockwise 600 degrees (1-2/3 turns) to position the crankshaft keyway in the 11 o'clock position. This will position the LH camshafts in the neutral position.
    
    
    

    

    Fig. Rotate the crankshaft clockwise 600 degrees (1-2/3 turns) to position the crankshaft keyway in the 11 o'clock position. This will position the LH camshafts in the neutral position-3.0L engine
12. Verify the LH camshafts are in the neutral position.
    
    
    

    

    Fig. Verify the LH camshafts are in the neutral position-3.0L engine
13. Remove the LH timing chain tensioner and tensioner arm:
    1. Remove the 2 bolts.
    2. Remove the tensioner.
    3. Remove the tensioner arm.
14. Remove the LH timing chain.
15. Remove the 4 bolts and the LH VCT assembly.
16. Remove the pulley bolt, washer and the crankshaft sprocket.

To install:

1. Install the crankshaft sprockets with the timing marks out.
   
   
   

   

   Fig. Install the crankshaft sprockets with the timing marks out-3.0L engine
2. Position the chain tensioner in a soft-jawed vise.
3. Hold the chain tensioner ratchet lock mechanism away from the ratchet stem with a small pick.
   
   WARNING

   During tensioner compression, do not release the ratchet stem until the tensioner piston is fully bottomed in its bore or damage to the ratchet stem will result.
   
   
   
   
   

   

   Fig. Hold the chain tensioner ratchet lock mechanism away from the ratchet stem with a small pick
4. Slowly compress the timing chain tensioner.
5. Retain the tensioner piston with a 1.5 mm (0.05 in) wire or paper clip.
   
   
   

   

   Fig. Retain the tensioner piston with a 1.5 mm (0.05 in) wire or paper clip-3.0L engine
6. If timing marks in the timing chains are not evident, use a permanent-type marker to mark the crankshaft and camshaft timing marks on the LH and RH timing chains.
   1. Mark any link to use as the crankshaft timing mark.
   2. Starting with the crankshaft timing mark, count counterclockwise 29 links and mark the link.
   3. Continue counting counterclockwise to link 42 and mark the link.
      
      
      

      

      Fig. Mark any link to use as the crankshaft timing mark (1). Starting with the crankshaft timing mark, count counterclockwise 29 links and mark the link (2). Continue counting counterclockwise to link 42 and mark the link (3)-3.0L engine
7. Verify that the LH camshafts are correctly positioned.
   
   
   

   

   Fig. Verify that the LH camshafts are correctly positioned
8. Install the variable camshaft timing (VCT) assembly and the 4 bolts. Tighten to 18 ft. lbs. (25 Nm).
9. Install the LH timing chain. Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.
   
   
   

   

   Fig. Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets
10. Install the LH timing chain tensioner arm and the LH timing chain tensioner:
    1. Install the tensioner arm.
    2. Position the tensioner.
    3. Install the 2 bolts and tighten to 18 ft. lbs. (25 Nm).
11. Install the crankshaft pulley bolt and washer and rotate the crankshaft clockwise 120 degrees until the crankshaft keyway is in the 3 o'clock position.
    
    
    

    

    Fig. Install the crankshaft pulley bolt and washer and rotate the crankshaft clockwise 120 degrees until the crankshaft keyway is in the 3 o'clock position
12. Verify that the RH camshafts are correctly positioned.
    
    
    

    

    Fig. Verify that the RH camshafts are correctly positioned
13. Install the RH VCT assembly and the 3 bolts. Tighten to 18 ft. lbs. (25 Nm).
14. Install the RH timing chain. Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.
    
    
    

    

    Fig. Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.
15. Install the RH timing chain tensioner and tensioner arm:
    1. Install the tensioner arm.
    2. Position the tensioner.
    3. Install the 2 bolts and tighten to 18 ft. lbs. (25 Nm).
16. Remove the LH and RH timing chain tensioner piston retaining wires.
17. Rotate the crankshaft counterclockwise 120 degrees to top dead center (TDC).
    
    WARNING

    Failure to verify correct timing drive component alignment will result in severe engine damage.
18. Verify the timing with the following steps.
    1. There should be 12 chain links between the camshaft timing marks.
    2. There should be 27 chain links between the camshaft and the crankshaft timing marks.
    3. There should be 30 chain links between the camshaft and the crankshaft timing marks.
       
       
       

       

       Fig. There should be 12 chain links between the camshaft timing marks (1). There should be 27 chain links between the camshaft and the crankshaft timing marks (2). There should be 30 chain links between the camshaft and the crankshaft timing marks (3).
19. Remove the crankshaft pulley bolt and washer.
    
    WARNING

    This pulse wheel is used in several different engines. Install the pulse wheel with the keyway in the slot stamped 30RFF only (orange in color).
20. Install the ignition pulse wheel.
21. Install the 6 spark plugs. Tighten to 11 ft. lbs. (15 Nm).
22. Install the engine front/timing chain cover

These details will help.

Thanks.

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Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html